Steering Shaft - Intermediate

Replacement of the intermediate steering shaft that connects the steering column to the steering rack on a 2005 Dodge Viper, addressing wear, binding, or clunking in the steering system.

Warnings

Tools required

Parts

• Intermediate steering shaft assembly × 1 — Mopar OEM or equivalent - verify spline count and length
• Intermediate shaft pinch bolt(s) × 2 — Use OEM specification if reusing is not recommended

Preparation

1. Park vehicle on level ground and apply parking brake.
2. Place wheel chocks behind rear wheels.
3. Turn ignition to ON position without starting engine, center the steering wheel precisely, then turn ignition OFF and remove key.
4. Raise front of vehicle with floor jack and support securely on jack stands at manufacturer-specified lift points.
5. Allow steering components to cool if vehicle was recently driven.

Procedure

1. 1

   Access Lower Steering Column Area
   From inside the cabin, remove the lower steering column cover. The cover is typically secured by 3-4 screws accessible from below the column. Set cover and fasteners aside in a secure location.
2. 2

   Mark Upper Shaft Alignment
   Locate the upper pinch bolt connecting the intermediate shaft to the steering column shaft. Using a white paint marker, make a clear alignment mark across both the intermediate shaft and the steering column shaft where they join. This ensures proper clocking during reassembly. Verify the steering wheel has not moved from center position.
3. 3

   Remove Upper Pinch Bolt
   Using the appropriate socket, remove the upper pinch bolt securing the intermediate shaft to the steering column. Apply penetrating oil if the bolt shows corrosion. Note the bolt orientation for reinstallation. Support the intermediate shaft as you remove the bolt to prevent it from dropping.
4. 4

   Access Steering Rack Connection
   Move to the underside of the vehicle. Working from below, locate the lower end of the intermediate shaft where it connects to the steering rack input shaft. Clean the area around the connection to identify the lower pinch bolt clearly.
5. 5

   Mark Lower Shaft Alignment
   Using a white paint marker, make a clear alignment mark across both the intermediate shaft lower U-joint and the steering rack input shaft. This is critical for maintaining proper steering geometry and preventing binding.
6. 6

   Remove Lower Pinch Bolt
   Remove the lower pinch bolt securing the intermediate shaft to the steering rack input shaft. Note the bolt orientation and any washers or spacers present. Support the intermediate shaft to prevent it from falling once the bolt is removed.
7. 7

   Remove Intermediate Shaft
   Carefully separate the intermediate shaft from both the steering column and steering rack input shaft. You may need to gently pry or wiggle the U-joint connections to release the splines. Remove the shaft assembly from the vehicle, noting its routing path and any clearance points for reinstallation.
8. 8

   Inspect Connection Points
   With the intermediate shaft removed, inspect the steering column output shaft and steering rack input shaft splines for wear, damage, or corrosion. Check the steering column support bearing (if equipped) for play or noise. Clean any debris from both shaft splines using a wire brush if needed.
9. 9

   Prepare New Intermediate Shaft
   Compare the new intermediate shaft to the removed unit to verify correct length, U-joint type, and spline configuration. Apply a light coat of multi-purpose grease to both splined ends of the new shaft to ease installation and prevent corrosion.
10. 10

    Install Lower Connection
    From under the vehicle, slide the lower end of the new intermediate shaft onto the steering rack input shaft, aligning the splines and the paint marks you made during disassembly. Ensure the shaft is fully seated on the splines. Insert the lower pinch bolt and thread it by hand, but do not fully tighten yet.
11. 11

    Install Upper Connection
    Move to the cabin and guide the upper end of the intermediate shaft onto the steering column output shaft. Align the paint marks made during disassembly and verify the steering wheel remains centered. Ensure the shaft is fully seated on the splines. Insert the upper pinch bolt and thread it by hand.
12. 12

    Torque Pinch Bolts
    Torque the lower pinch bolt to the manufacturer-specified value (verify exact spec in the 2005 Dodge Viper service manual before tightening). Then torque the upper pinch bolt to the specified value. Verify both connections are tight and properly seated with alignment marks still matching.
13. 13

    Verify Steering Operation
    Before reinstalling covers, turn the ignition to ON (do not start engine) and slowly rotate the steering wheel lock-to-lock while observing the intermediate shaft for binding, noise, or interference. The shaft should move smoothly through its entire range. Verify the steering wheel returns to center position.
14. 14

    Reinstall Steering Column Cover
    Reinstall the lower steering column cover and secure with the original fasteners. Ensure the cover fits properly without interfering with steering shaft movement or pedal operation.

Reassembly

1. Lower vehicle from jack stands carefully.
2. Remove wheel chocks.
3. Start the engine and verify power steering operation if equipped.
4. Perform a slow-speed test drive in a safe area to verify smooth steering operation with no binding, clunking, or abnormal noises.
5. Check steering wheel alignment and verify it returns to center after turns.

Verification

• Confirm steering wheel remains centered when driving straight.
• Verify no clunking, binding, or unusual noises when turning the steering wheel at idle or while driving.
• Check that both pinch bolts are torqued properly and alignment marks are still matched.
• Verify steering wheel returns to center smoothly after turns.
• Confirm no steering angle sensor fault codes are present (use scan tool if available).

Related trouble codes on this vehicle

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